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The International Journal of Advanced Manufacturing Technology

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13.08.2019 | ORIGINAL ARTICLE

Residual stress prediction in selective laser melting

A critical review of simulation strategies

verfasst von: Leonardo Bertini, Francesco Bucchi, Francesco Frendo, Mattia Moda, Bernardo Disma Monelli

Erschienen in: The International Journal of Advanced Manufacturing Technology | Ausgabe 1-4/2019

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Abstract

This review focuses on the analysis of numerical models aimed at predicting the residual stress-strain field produced by the selective laser melting process. Our first intent is to favor an intuitive understanding of the underlying physics and then to provide an overview of the available simulation strategies specifying their field of application. In fact, given the complexity and the multi-scale nature of the process, various tailored models are needed for the assessment and prediction of defects and manufacturing issues arising during the building phase. Regarding the estimation of residual stresses, the available models were reviewed and classified on the basis of the dimensional scale of the simulated phenomena. Meso-scale models perform the detailed simulation of the scanning process, but the high computational cost currently prevents their application on the whole build volume (the current limit on the scanning volume is approximately 100 mm³ with dynamic mesh coarsening techniques). Macro-scale models have been developed to overcome this limit by introducing deep simplifications of the thermo-structural problem. From our review, it appears that meso-scale modeling has reached a significant maturity, while a widely adopted strategy for macro-scale simulations has not emerged yet.

Vorheriger Artikel Data-driven CBM tool for risk-informed decision-making in an electric arc furnace

Nächster Artikel Emissivity calibration method for pyrometer measurement of melting pool temperature in selective laser melting of stainless steel 316L

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Defined by the design rules for additive manufacturing [1, 2, 122].

Evolution of the composite material concept.

Consisting in localized fusion and subsequent solidification of thin metallic powder layers.

Properly designed heat treatments may produce static mechanical properties comparable with the ones of conventional forged or cast materials (usually maintaining higher tensile strengths, but lower fracture strains) [9, 99, 123, 125].

Transverse electric and magnetic (TEM) mode.

The density of radiation incident on a given surface usually expressed in Watts per square centimeter or square meter [87].

Pure analytical procedures (such as the one presented here) can be useful to understand the main physical phenomena and formulate educated guesses, but parameter fine-tuning and design space explorations require a combination of analytical, numerical, and structured experimental approaches.

Evaluated on the midplane of the powder layer.

The depth at which the magnitude of the electric (or the magnetic) field inside the material decayed to e^− 1 of its surface value, and the radiation power (proportional to the square of a field quantity) decreased to e^− 2 (about 13.5%) of its surface value.

Heat-affected zone.

Partial differential equation(s).

Finite element method.

Finite difference method.

Lattice Boltzmann method.

Degree of freedom.

Constant temperature.

Surface heat sources.

Both linear (e.g. convection) and non-linear (e.g. radiation).

Defined as the reciprocal of the variance; for the Gaussian standard normal distribution τ = 2.

Electron beam melting.

Additive manufacturing.

More properly gas filled.

Which instead affect the lattice vibrational component of the conductive heat transfer.

Homogeneous or with homogenized properties.

Composed of a yield criterion with the corresponding loading-unloading condition, a flow rule, and a hardening model.

Laser displacement sensor.

Strictly speaking, a loss of accuracy and resolution is produced by the coarsening procedure.

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Titel: Residual stress prediction in selective laser melting
A critical review of simulation strategies
verfasst von: Leonardo Bertini
Francesco Bucchi
Francesco Frendo
Mattia Moda
Bernardo Disma Monelli
Publikationsdatum: 13.08.2019
Verlag: Springer London
Erschienen in: The International Journal of Advanced Manufacturing Technology / Ausgabe 1-4/2019
Print ISSN: 0268-3768
Elektronische ISSN: 1433-3015
DOI: https://doi.org/10.1007/s00170-019-04091-5

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